Closure system for disposable absorbent article

ABSTRACT

A closure system and method of making a closure system for a disposable article. A substantially continuous closure system web is provided. One face of the web is provided with first fastening region at terminal end portion(s) of the web. A second fastening region, engagable with the first fastening region, is provided on a second face of the web in a region adjacent the terminal end portion(s). The closure system tab elements are cut from the web and attached to a second web, used in producing the disposable article, at longitudinally spaced locations. This second web is then cut at transverse cut lines separating the closure system tab element into two functional elements. A first functional element has a fastening tab portion and the second functional element has an attachment portion. The attachment portion of one closure system tab element interacts with a fastening tab portion of an adjacent closure system tab element to form a functional closure system on a disposable article made using the second web.

BACKGROUND AND FIELD OF THE INVENTION

The present invention relates to a closure system for a disposableabsorbent article, particularly multifunctional closure systemsattachable to the waistband portions of the disposable absorbentarticle.

In the field of disposable absorbent articles, typically disposablediapers and adult incontinent articles, closure systems are providedwhich generally are formed using pressure sensitive adhesive fasteningtabs or mechanical fastening tabs. These tabs are generally attached tothe disposable absorbent article at corner portions at at least one endof the article, e.g., a diaper. The typical fastening tabs have one endwhich is permanently bonded to the absorbent article and a second freeend which is available for the user to removably attach to the opposingend of the article to effect closure. The opposing end of the absorbentarticle typically is provided with a mating attachment surface. In thecase of pressure sensitive adhesive fastening tabs, the matingattachment surface typically is a reinforcement film or other materialwhich is applied to the inside or outside face of the outer liquidimpermeable layer of the disposable absorbent article. In the case of amechanical fastening tab, the mating attachment surface is a loopfastening material which must be placed on the outside face of theliquid impermeable outer cover layer of the disposable absorbentarticle. In either case, the mating attachment surface is typicallyprovided by applying a separate discrete element to the absorbentarticle. This could be a pressure sensitive adhesive element or anon-adhesive coated element bonded by other means such as hot meltadhesive or thermal welding. In certain extreme cases, the entire outerface of the disposable absorbent article can be provided with a suitablemating attachment surface for the fastening tab second free end, howeverthis can be excessively costly. The fastening tab itself is also appliedas a separate and discrete element to the corner of the disposableabsorbent article, generally at the back end region. Generally, thispermanent attachment of the fastening tab is made by a pressuresensitive adhesive applied at one end of the fastening tab with theother second end of the fastening tab provided with a suitable pressuresensitive adhesive or mechanical fastening element for releasableattachment and closure of the absorbent article. The fastening tab canbe applied as a separate piece cut from a roll which can be laminatedwith other suitable materials, such as a release tape, during themanufacture of the diaper. Alternatively, the fastening tab can beprovided with other suitable components in a pre-laminate form whichalso is cut from a continuous roll. These closure systems are highlyeffective but can be complicated, particularly when they are laminatedon the diaper line and/or additional functionality is incorporated intothe fastening tab, such as elasticity.

It has also been proposed in the patent literature that suitable beltmeans could be provided with attachment elements at the opposing ends ofthe belt to provide a closure system for use with a disposable absorbentarticle. Belts can address some of the issues regarding separate tabfasteners as some only require the use of a single laminate or the likewhich can be securely or releasably attached to a diaper absorbent pador the like. However the use of two interconnecting belts have also beenproposed. In U.S. Pat. Nos. 3,847,702 and 3,561,446, an inextensiblebelt material is provided both to the front and back ends of adisposable diaper. Each belt extends across the full width of the diaperand both belts are provided at the terminal ends with a pressuresensitive adhesive region which adhesive is covered until use with arelease tape. When the diaper is closed, one belt is attached to someportion of the second belt at the opposite end of the diaper, and theadhesive on the terminal ends of the second belt is generally attachedto the diaper on the diaper face opposite that provided with the firstbelt. These belts prevent inelastic deformation of the waistband regionof the diaper during use. However, this two-belt system would be similarin manufacturing complexity to the use of tab fasteners.

French Pat. Nos. 2,586,558, 2,725,879, and PCT Publ. No. 94/26224 teachthe use of only one inextensible belt which single belt can be attachedto the front or rear ends of the diaper, either permanently or byrefastenable mechanical fastening elements. When the diaper isrefastenably attached to the belt, the belt can be reused repeatedly. Inthese patent documents, the belt generally wraps around the wearer andsecures to itself with the diaper being releasably attached to the beltat least at one end of the diaper, and either releasably or permanentlyattached to the belt at the opposing end of the diaper. A similarapproach is proposed in U.S. Pat. No. 4,964,860, and PCT application No.91/08725 where a reusable belt with mechanical fastening elements isused with a disposable diaper provided with mating mechanical fasteningelements. These belts can be relatively easy to incorporate onto adiaper but lack the ease of use of a fastener tab closure system for theend user.

In EP Appln. No. 528282, a permanent integral waistband is provided on adiaper which waistband could be stretchable. The waistband is on one endof the diaper and wraps around the wearer's waist and attaches to itselfforming a belt. Both the waistband and the front portion of the diaperare provided with suitable interengagable attachment elements 44 and 50which could be any variety of attachment means including pressuresensitive adhesives, cohesive adhesives, and mechanical fasteners. Thefront portion of the diaper would attach to the waistband portion. Thispatent attempts to combine some of the benefits of a single beltedsystem with those of a tab fastening closure system.

In U.S. Pat. No. 5,593,401, a bridging type element is provided at oneend region of a diaper as a separate element to which may be attachedtwo conventional fastening tabs at either end. The bridge strip has asecured side and an unattached side and is generally described as beingelasticized. This bridge strip would require a separate attachment stepand associated apparatus in order to be integrated into the disclosedconventional diaper constructions. This is similar to the above two beltsystems but is more complicated in terms of its construction andmanufacture.

Elasticized waist elements which may have attached fastening tabs thatthen releasably attach to a front panel portion of a diaper aredisclosed in U.S. Pat. No. 4,998,929, and PCT Publ. Nos. WO 96/32083,and WO 95/22951. An elastic type belt element which wraps around theentire waist of the wearer and which is provided with inter-engagingmechanical fastening elements at its terminal ends is disclosed in U.S.Pat. No. 5,607,416. In all the above patent documents, there is aseparate and distinct elastic element with the terminal edges generallyincluding an attachment element such as a pressure sensitive adhesive ora mechanical fastening element which attaches to the elastic belt as perU.S. Pat. No. 5,607,416 or to a suitable attachment mechanism on theother end portion of the diaper or like disposable absorbent article.

The use of two or one belt closure systems that wrap around one end of adiaper or the entire waist of the wearer, respectively, are desirablefrom a number of perspectives. The belt can be used with the closuresystem in a manner that provides other functionality such as elasticityor inextensibility that is actively integrated with the closure system.However, the means proposed for providing these belt and closureelements generally requires a number of separate attachment steps on themanufacturer's line.

The invention is directed at addressing the manufacturing complexitiesof multicomponent closure systems by enabling the provision of aneffective closure system by a single attachment step which can alsoprovide additional desired functionality such as inextensible beltelements, extensible belts or bands, elasticity, and the like. Theinvention is also directed at a method of providing a diaper closuresystem and optionally a belt system on a diaper line by the use of asingle closure system laminate.

BRIEF DESCRIPTION OF THE INVENTION

The invention comprises a closure system and a method of forming aclosure system for a disposable absorbent article. The method comprisesthe steps of providing at least one substantially continuous web capableof forming a portion of a disposable absorbent article. The web has afirst width dimension defining two side edges and an indefinite lengthdimension. A closure system web is also provided comprising at least onebacking having a first face and a second face. The closure system webhas a second width dimension generally greater than the first widthdimension and an indefinite length. The first face of the closure systemweb is provided with at least one first fastening region at at least oneterminal end portion of the closure system web. At least one secondfastening region is provided on the second face of the closure systemweb in at least the second portion adjacent the terminal end portionprovided with the first fastening region. Closure system tab elementsare cut from the closure system web, which tab elements have a definitelength dimension. The closure system tab elements have at least onefastening tab portion, comprising the at least one first fasteningregion on the terminal end portion, and an attachment portion comprisingthe second portion having the second fastening region.

The closure system tab elements are then attached to the at least onesubstantially continuous web at regular spaced intervals along theindefinite length dimension in a continuous manner. The at least onecontinuous web is then cut along cut lines transverse to the indefinitelength dimension to form discrete disposable absorbent articles. Thetransverse cut lines are such that they bisect the closure system tabelements along the tab element definite length dimension, so that thefastening tab portion is on a first side of the transverse cut line andthe attachment portion is on a second opposing side of the cut line.This provides fastening tab portions on a first end of one absorbentarticle and an attachment portion on a second end of an adjacentabsorbent article.

A closure system of the invention is used on a disposable absorbentarticle having a first width dimension defining two side edges and twoend edges. The closure system comprises at least one fastening tabhaving a backing. A first face of the fastening tab backing is providedwith at least one first fastening region at at least a first end. Atleast one second fastening region is provided on a first face of anattachment portion having a backing. The attachment portion has a topedge and a bottom edge. Preferably at least a discrete portion of theattachment portion top edge is laterally coextensive with a portion of afirst end edge of the disposable absorbent article. A corresponding andcoextensive discrete portion of a bottom edge of the at least onefastening tab is also preferably laterally coextensive with a second endedge of the disposable absorbent article. At least a portion of theattachment portion top edge is laterally coextensive with the bottomedge of the at least one fastening tab which both preferably form aportion of, or are adjacent to, end edges of the disposable absorbentarticle. The respective backings of the at least one fastening tab andthe attachment portion are identical, at least at an area adjacent thetwo discrete coextensive edge portions of the at least one fastening taband the attachment portion.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side cross sectional view of a first embodiment of a closuresystem web used in the present invention.

FIG. 2 is a top perspective cut away view of a portion of a closuresystem web such as shown in FIG. 1.

FIG. 3 is a cut away schematic view of an apparatus for forming theclosure system web of the invention such as shown in FIGS. 1 and 2.

FIG. 4 is a top perspective view of a second embodiment of a closuresystem web in accordance with the present invention.

FIGS. 5-7 are top perspective views of three further embodiments ofclosure system webs in accordance with the present invention.

FIG. 8 is a top perspective view of further embodiment of a closuresystem web in accordance with the present invention having a doublewidth.

FIG. 9 is a top perspective view of a further embodiment of a closuresystem web in accordance with the present invention.

FIG. 10 is a top perspective view of a further embodiment of a closuresystem web in accordance with the present invention.

FIG. 11 is a top perspective view of a further closure system web inaccordance with the present invention.

FIG. 12 is a top perspective view of a FIG. 11 embodiment as it would beapplied to a web 41 forming a disposable absorbent article.

FIGS. 13-15 are side cross sectional views of further embodiments ofclosure system webs in accordance with the present invention.

FIG. 16 is a top perspective schematic view of how the closure systemwebs of the present invention would be cut out and applied as tabelements in the formation of disposable absorbent articles from acontinuous web 41.

FIG. 17 is a top perspective view of a further embodiment of a closureweb in accordance with the present invention.

FIG. 18 is a top perspective view of a further embodiment of a closureweb in accordance with the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The instant invention is directed at providing a fully functionalclosure system for a disposable absorbent article, integrated with theprocess of forming the disposable absorbent article, by attachment ofunitary closure system tab elements. The tab elements are cut from acontinuous closure system web product and then attached to a continuousor substantially continuous absorbent article web from which discretedisposable absorbent articles are eventually cut. These closure systemtab elements provide both the fastening tabs and a suitable matingattachment surface for the disposable absorbent articles. However thefastening tabs and mating attachment surface of a single closure systemtab element end up on different absorbent articles when the absorbentarticles are cut from the absorbent article web.

A first embodiment of a closure system web product, in cross section, isshown in FIG. 1, which comprises a laminate of a backing layer (2)having a first face provided with a pressure sensitive adhesive layer(9). Adhesive layer (9) is used for eventual attachment of the closuresystem tab elements to the disposable absorbent article web. Attached tothe backing (2) at terminal end portions are first fastening regions. Inthe FIG. 1 embodiment the first fastening region is provided by a hookmechanical fastening material (4) formed from hook mechanical fasteningelements (7) projecting from a hook backing (6). However the fasteningregion can be formed directly on the backing (2) rather than beingattached as a separate element by, for example, use of an adhesive asshown in FIG. 1. The second face of the backing (2) in FIG. 1 isprovided with second fastening region comprising a mating loopmechanical fastening material (8) which would engage with the hookmechanical fastener material (4). These two mating fastening materialstogether form a unitary closure system when applied to a diaper web, orthe like, in accordance with the invention.

The closure system tab elements (14) are cut from the continuous closuresystem web (1) along cut lines (15) as shown in FIG. 2. The closuresystem web (1), and the closure system tab elements (14) cut therefrom,have a width dimension (31) which is divided into terminal end portions(32) and a second portion(s) (33). Although the terminal end portions(32) can be at the side edges of the closure system web, as shown inFIG. 2, they can also be provided at intermediate regions of a closuresystem web as shown in FIGS. 8 and 11. The closure system web (1),generally has an indefinite length direction (L), however, the closuresystem tab elements (14) cut from the web (1) generally have a definitelength dimension (16) which is preferably constant across the majorityof the width (31) of the closure system tab element (14), and ispreferably constant over at least the entire second portion (33).

If closure system tab elements (14) vary in length (16) across theirwidth, two separate cut lines must be provided to define the top andbottom of adjacent closure system tab elements. This requires materialwaste or selvage between the two separate cut lines. If a single tabelement cut line defines both the top and bottom of two adjacent tabelements (14), there is no waste, but the length (16) of the tabelements will be constant across the width of the tab element along theshared boundary defined by the single tab element cut line (exceptpossibly in the special case where the tab element cut lines areparallel to the length direction, in which case the width would includethe length of the cut line). However, inevitably the tab element cutline is not straight and does vary in the length direction of thecontinuous web so that the terminal end portions (32) are offset fromthe second portion (33) in the length dimension. The average offset isat least 10 percent of the maximum length of the terminal end portionspreferably at least 50 percent.

On the terminal end portion (32) is generally provided the firstfastening region, which in the case of FIG. 2 is hook mechanicalfastening material (4) which engages with a mating second loopmechanical fastening material (8) on an attachment portion of the secondportion (33). In FIG. 2 the second fastening region forming theattachment portion is the loop material (8).

The closure system tab elements (14) when cut from the closure systemweb (1) provide unitary structures which are attached to a continuous orsubstantially continuous web used in forming the absorbent articles at alocation having the above first width. As shown in FIG. 16, the outerbacksheet web of a diaper can form the continuous web. A continuous web,as shown in FIG. 16, is either assembled, or will be assembled, withother components to form a continuous disposable absorbent article web.From this disposable absorbent article web discrete disposable absorbentarticles are cut. For example, these other components, in addition tothe backsheet web, can include an absorbent batt material, a fluidpermeable top sheet, a fluid transport layer or similar continuous orsubstantially continuous web elements which are conventionallyintegrated into the manufacture of a disposable absorbent article. Also,other discrete elements can be attached to the continuous web(s) such asfurther tab elements, elastics such as leg or waist elastics, liquidbarriers, reinforcement elements, or the like.

The continuous web as shown in FIG. 16 is a backsheet web but othercontinuous webs could be used for attachment of the closure system tabelements; for example, nonwoven cover sheets, liquid pervious topsheets,or the like. Also, the continuous or substantially continuous web towhich the closure system tab elements is attached could be nonplanar,laminated to other webs, or composites created by a lamination ofmultiple discrete components. A substantially continuous web can also beused having short regions of discontinuity creating web elements thatgenerally are sequentially arranged and continuously supported, at leastin the region where the closure system tab elements are attached.However, in this embodiment, when the closure system tab elements areattached to the discrete continuously supported web elements, the webelements and the attached closure system tab elements will form acontinuous web at least in the region between where the closure systemtab elements are attached and the discrete absorbent articles are cutand/or the closure system tab element are bisected.

In FIG. 2, the numeral (10) indicates the side edges of the at least oneabsorbent article continuous web (41) to which the closure system tabelements (14) are attached at discrete longitudinally displacedlocations along the length of an at least one absorbent articlecontinuous web (41), as shown in FIG. 16. The continuous web (41) isthen cut into discrete absorbent articles along transverse cut lines(11) which transverse cut lines generally also bisect or cut the closuresystem tab elements (14) as shown, e.g., in FIGS. 2 and 16. However, itis possible to bisect the closure system tab element before cutting thediscrete absorbent article by, for example, bisecting the closure systemtab elements as part of a continuous web and attaching these discreteelements to a further web from which the discrete absorbent articles areeventually formed. When the discrete absorbent articles are cut, theterminal end portions (32) and a portion of the second portion (33)forming a bridging element or band (95 or 12) remain attached to a firstdisposable absorbent article (90) with a majority of the second portion(33) remaining on an adjacent disposable absorbent article (91), formingthe attachment portion (93 or 13).

The terminal end portions (32) have a first end (17) which projectsoutwardly beyond the side edges (10) of the disposable absorbent articleand a second end (18), which remains permanently attached to thedisposable absorbent article web (41). At least a portion of the firstend (17) contains the first fastening region, such as the hook material(4) in FIG. 2. The mating loop material (8) on the second portion (33)attachment portion (93 or 13), when attached to continuous web (41),forms the mating mechanical fastening surface on the adjacent absorbentarticle (91) which in conjunction with the next downweb closure systemtab element terminal end portions (32) forms a unitary closure system ona disposable absorbent article (90).

Generally, the attachment portion (93) is attached to the front region(96) of a disposable absorbent article or the like. The terminal endportions (32) containing the first fastening region are attached to aback portion (97) of the disposable absorbent article. However, thefront and back portions are determined by how the article is attached,which can be determined by the user. As such, the front portion could beused as the back portion if the absorbent article is generallysymmetrical and the user so chooses.

The terminal end portions (32), provided generally on only a first sideof the traverse cut line (11), form fastening tab portions (99) on adisposable absorbent article. These fastening tab portions, as shown inFIGS. 2 and 16, can be interconnected by, or include, a portion of thesecond portion (33). When these portions of the second portion (33)interconnect two fastening tab portions, they act as a bridging portionor band (12 or 95) around a front or back peripheral edge of thedisposable absorbent article (91). Consequently, when the fastening tabportions (99) are attached to the attachment portion (13 or 93) acontinuous band is formed around the peripheral edge of the disposableabsorbent article formed by the front portion (96) and the back portion(97). This bridging portion or band (12 or 95)can be in whole or in partinextensible, extensible and/or elastic depending on the materialforming the backing layer (2).

The bridging element or band (12 or 95) can provide functionality suchas inextensibility if a suitable backing (2) is selected.Inextensibility is desirable in that the garment, such as a diaper, canpermanently stretch when it is worn. This stretching results in a loosefit and possibly leakage, or even the diaper falling off. If acontinuous inextensible band is provided around the diaper thisstretching can be minimized or eliminated. Elasticity in the bridgingelement(12 or 95) can also address stretching by positively engaging thewearer around the waist, providing an elastic recovery force. In thiscase, all or a portion of the backing (2) is provided to be elastic, andthe closure system tab elements (14) are applied in a manner as isconventional for a waist elastic or like elastic components.

FIG. 16 is a schematic illustration of a continuous web, of thedisposable absorbent article (41), to which is attached the closuresystem tab elements (14) such as depicted in FIGS. 1 and 2. The terminalend portions (32) when cut from the attachment portion (13 or 93) of thesecond portion (33) by the transverse cut line (11) forms two fasteningtab portions (99), connected by a bridging element (95), at the terminalside edges (10) of the disposable absorbent article (91) cut from theweb (41). The second portion (33) attachment portion (13 or 93) formsthe mating attachment surface second fastening region to which thefastening tab portion (99) first fastening region adheres. Thetransverse cut line (11) bisects the closure system tab element (14)along its definite length dimension (16) such that a fastening tabportion (99) and bridging element (12 or 95) is on one side of thetraverse cut line (11), and the attachment portion (13 or 93) is on thesecond opposing side of the traverse cut line. A unitary closure systemis formed on a single disposable absorbent article (91) by therespective fastening tab portions (99) on a first side of the transversecut line of a first closure system tab element (14) in combination withthe adjacent attachment portion (93) cut from the second opposing sideof a second adjacent closure system tab element (14).

Generally, the fastening tab portion maximum length is from 2 to 10 cmlong, preferably from 2 to 5 cm long and from 2 to 20 cm wide,preferably from 5 to 15 cm wide based on the size of the article.However, the first fastening region can be from 0.5 to 5 cm long onaverage, preferably from 1 to 4 cm long or arranged to provide a crosssectional area of from 0.25 to 25 cm², preferably from 1 to 10 cm². Theportion of the fastening tab portion permanently attached to the articleincludes the terminal end portion (32) second end and possibly a portionof the second portion (33). Overall, the minimum width of the fasteningtab portion (99) second end permanently attached to the diaper is from 1to 5, preferably from 2 to 4 cm.

The overall length of the attachment portion (13, 93) is preferably atleast 40 to 95 percent of the length of the first fastening region,preferably 60 to 90 percent. The length of the bridging element can varyacross its width, as can the length of the attachment portion. Theaverage length of the attachment portion can range from 5 to 100 cm,preferably from 10 to 50 cm. Overall, the maximum length (16) of theclosure system tab element can vary as required and could be from 10 to200 cm, preferably from 20 to 100 cm. The bridging member length can bezero, or close to zero, where it provides no functionality as acontinuous belt element. However if the bridging element functions as anelastic band or an inextensible band or the like, it is generally has aminimum length of at least 0.5 cm and generally at least 1 cm to 5 cmlong. The bridging element average length generally is less than theaverage length of the attachment portion. Preferably, the average lengthof the bridging element is less than 40 percent of the average length ofthe attachment portion. The bridging element and the attachment portion,if combined, will generally form a rectangular shape, when the tabelements are separated by a single cut line in the second portion. Assuch, the bridging element and the attachment portion are generallynegative inverted mirror images of each other.

FIG. 3 illustrates a method for forming the closure system web of FIGS.1 and 2 having hook and loop fastening regions using the methodssubstantially described in U.S. Pat. No. 5,256,231 to form the loopfastening region. By this method, a sheet of fibers (3), which can be anon-woven web, used to form the loop material (8) is fed by conventionalmeans, such as from a supply roll or directly from a web-formingprocess, between a pair of mutually parallel intermeshing rollers (25and 26) which are provided with intermeshing teeth. These teethintermesh in the manner of gear-teeth with ridges on one roll fittinginto valleys on the adjacent roll, and visa versa. As shown in FIG. 3,these intermeshing teeth can be aligned radially along the length ofrollers (25 and 26), however, these gear teeth could also be arranged innumerous other regular intermeshing patterns including circumferentiallyextending gear teeth along the diameter of rollers (25 and 26), or inmating geometric patterns such as diamonds, hexagons, squares, circles,or any other regular or irregular pattern where the peak portions of apattern on one roll intermesh with the valley portions of a pattern onthe adjacent roll. Upon exiting from the nip (24) formed by rolls (25and 26), the sheet of fibers is retained along the periphery of the roll(26) such as by applying web tension, vacuum, differentially heatingroll (26) and/or roughing the surface of roll (26). At this point, thesheet of fibers (3) is maintained in its deformed or corrugated stateand is given dimensional stability by joining with a dimensionallystable web material such as a film or a dimensionally stabilized wovenor non-woven fabric. Alternatively the corrugated sheet of fibers can bemade to be elastic or extensible by being joined to an elastic orextensible web material which web material can form the closure systemweb backing (2).

As shown in FIG. 3, the corrugated loop material (8) retained on thesurface of roll (26) is directly joined to a molten extruded filmmaterial (23) which is formed in a die provided with a die opening (22).The extruded film material (23) being still in a molten, or semi-moltencondition is sufficiently soft to allow the sheet of fibers (3)corrugated on roll (26) to become embedded within the extrudate. Thisprovides secure bonding and also dimensional stability or otherproperties based on the properties of the film backing (23) and anyfurther layers provided (not shown). The backing roll (27) forms a nipwith roll (26), which roll (27) is generally a cooled, smooth roll. Thenip pressure is preferably substantially constant across the width ofthe laminated web material formed at least by the corrugated sheet offibers (8) and the extrudate (23). Additional cooling rollers could beprovided or the laminate could be further wrapped around roller (27) toprovide further cooling as desired. The laminate backing (2) is thenfurther coated with adhesive (9) using an adhesive coater (29), whichcan be a pressure sensitive adhesive. Adhesive (9) can then be used toadhesively bond the mechanical fastening material (4) to the backing(2). The mechanical fastening material (4) can also be previouslyadhesively coated and then joined with the laminate web backing (2) orattached by other mechanisms including sonic bonding, point bonding,sewing, or the like.

If a pre-formed web material is provided as the backing (2), the nip(28) formed between rolls (26 and 27) is preferably heated so as tothermally bond the sheet of fibers (8) to the pre-formed backingmaterials, such as by providing rolls (26 or 27) with heating elementssuch as an oil heated roll, a water heated roll, an induction heatedroll, or an ultrasonic horn.

An alternative embodiment of providing the invention closure system tabelements (14) is depicted in FIG. 4, with the fastening tab portion (34)first end (37) on the terminal end portion (32) provided with smoothouter side edges (30). The closure system tab elements (14) are also cutinto a slightly modified form along the cut pattern (35) by providing aregion (5) where the cut line pattern slowly tapers from a portion (46)of the cut line separating two adjacent terminal end portions to anoffset portion (47) of the cut line (35) separating the attachmentportion from the bridging portion (38). In this embodiment, again thesubstantially constant length (16) of the closure tab element (14)extends across the majority of the width of the closure tab element (14)and over the entire width of the second portion (33). However, thefastening tab portion (34) or terminal end portion (32) first end (37)tapers in length. The tapered first end (37) on the terminal end portion(32) can be formed by removing a portion of the terminal end portionsuch as shown in FIG. 6 and/or by suitably nested cut patterns as shownin FIG. 8. The curved side edge (30) of the first end (37) eliminates orreduces the presence of sharp comers which can cause discomfort for thewearer of the disposable absorbent article if such sharp corners come incontact with the skin. The first end (37) containing the at least firstfastening region hook material has an average length (36). The fasteningtab portion (34) on terminal end portion (32) first end (37) ispreferably provided so that no sharp corner portions extend out beyondthe edge (10) of the continuous web (41) used in forming the disposableabsorbent article (91). In that, the length of the closure system tabelement (14) varies in the first end (37), there is a need for divergingcut lines in this region which requires waste or selvage of a certainportion of closure system web material in the first end region in thisembodiment.

FIG. 5 depicts a variation of the FIG. 4 embodiment where the taperedregion (5) of the cut pattern of the closure system web (1) has shiftedoutward slightly at the top portion. Also, the loop material (8) and/orthe sheet of fibers has been extended outward so that it covers theentire terminal end portions, from which are formed the fastening tabportions (34).

FIG. 6 shows a further embodiment similar to that shown in FIG. 4, wherethere is shown a cut out region or selvage (42) to be removed from theterminal end portions of the closure system web (1). In this embodiment,the cut line (45) in the second portion (33) is in the form of asubstantially continuous arc forming a generally semi-circularattachment portion (46). The bridging portion (40) interconnecting thetwo terminal end portions (47) is a corresponding concave structure.

FIG. 7 illustrates a further embodiment of a closure system tab elementdesigned in accordance with the invention wherein the attachment portion(56) is in the shape of a rectangle, also providing a rectangularbridging element or band (50) from the second portion (33). Theindividual closure system tab elements (14) are cut along the tabelement cut line (55) providing fastening tab portions with a curvededge (30) on the first end (17) and a rectilinear second end (18).

The embodiment shown in FIG. 8 shows an alternative for producingrounded edge (30) fastening tab portion first ends on a multiple widthclosure system web provided with multiple terminal end portions andsecond portions. With the terminal end portions at the outside edges ofthe closure system web the fastening tab portion curved side edges (30)are still provided by removal of selvage material. However, withintermediate terminal end portions, two nested curved side edges (30)can be provided by a single sinusoidal or like undulating cut line asshown in FIG. 8. The FIG. 8 embodiment results in two secondary closuresystem webs (56) cut from a single multiple width primary closure systemweb. The two secondary closure system webs (56) can be simultaneously orsubsequently cut into closure system tab elements (14), as disclosed inthe other embodiments of the invention.

As shown in FIG. 8, the intermediary terminal end portions curved sideedges are provided by a single sinusoidal or like undulating cut linesuch that the fastening tab portion first ends having the firstfastening regions nest without any wasted material or selvage. However,if desired, an intermediate waste or selvage region can be provided,particularly where the first fastening region is asymmetrical across itswidth dimension. For example, the base of the fastening tab portionfirst end and/or the first fastening region can be distinct anddifferent from the outer tip of the fastening tab portion first end. Inthe FIG. 8 embodiment, the curved portion of the fastening tab portionfirst end is symmetrical in that a continuous first fastening region isprovided across the entire width of the curved portion of the fasteningtab portion first end. An asymmetrical fastening tab portion first endcould also be provided. For example, the first end could be providedwith two distinct different attachment regions along it's width, such asa combination of a mechanical fastening region with an adhesivefastening region. Alternatively, a single region with no fastening meanscould be provided such as a finger lift region at the tip of the firstend which region is not reciprocally provided at the base of thefastening tab portion first end. These and other asymmetricallyfastening tab designs cut from a multiple width closure system web wouldgenerally require the provisions of two adjacent terminal end portionsfirst ends in the central portion of the closure system web withseparate cut lines for each to provide the desired asymmetricalfastening tab portions first ends on the two or more secondary closuresystem webs.

In the embodiment depicted in FIG. 9, the cut out fastening tab portionfirst end has been folded back onto the closure system web, which can bedone simultaneously with or following cutting out of the closure systemtab elements. The fastening tab portion first end is preferably foldedalong the lines separating the first end from the second end where thefirst end is designed to removably adhere to the mating second fasteningregion on the attachment portion and the second end is designed topermanently attach to the disposable absorbent article. The FIG. 9embodiment again is exemplified using a hook and loop type mechanicalfastening closure system for the first and second fastening regions.

An alternative to the FIG. 9 embodiment is shown in FIG. 17 wherein thefastening tab portion first end provided with the first fastening regionis folded away from the second fastening region rather than toward it.In this case, the fold is preferably away from the line separating thefastening tab portion first end and second end. The folded portion ofthe fastening tab portion first end is preferably entirely within anonfolded portion of the fastening tab portion first end. This ensuresthat the folded portion does not get between the backing and thedisposable absorbent article when the tab element is attached.

FIG. 18 is an alternative of the invention where the tab element is in ageneral chevron form. This embodiment would not have a bridging elementand the second portion would have a general v-shape when on thedisposable absorbent article.

FIG. 10 is an alternative embodiment of the invention where two firstfastening regions (71) and (72) are provided, both in this case hookmechanical fastening regions; one at the terminal end portion first end(17) and a second at the outer side margins (61) of the attachmentportion (60) in the second portion (33). The first fastening region (71)provided at the terminal end portion first end (17) would be on a firstface of the backing, whereas the second first fastening region (72)would be provided on a second face of the backing adjacent theattachment portion (60) on the second portion (33).

In the FIG. 10 embodiment, the two first fastening regions (71 and 72)are provided by hook mechanical fastening material with the secondfastening region provided by loop mechanical fastening material whichforms the attachment portion for the first fastening region (71) on theterminal end portion first end (17). The second first fastening regionhook mechanical fastening material (72), provided adjacent theattachment portion (60), on the second portion (33) can be used tointerengage with suitable loop or non-woven materials provided on a faceof the disposable absorbent article opposite that attached to theterminal end portion or fastening tab portion second end (18). Thissuitable loop or non-woven material is generally located on a side edgeregion of the disposable absorbent article adjacent or subjacent to theregion of the article attached to the second end (18) of the fasteningtab portion and can be a separately applied loop material or a nonwoventopsheet type material.

Generally, in the above described embodiments, the overall shape of theclosure system tab elements is a v or u, or like shape, however, othershapes are possible, including w-shapes.

FIG. 11 depicts an alternative embodiment of the invention wherein theterminal end portions are provided in a central region of a closuresystem web. The fastening tab portion first end on the terminal endportion is symmetrical in FIG. 11 so a single cut line can be used toform the first end curved end side edge (30) as described above relativeto the FIG. 8 embodiment. The fastening tab portion is provided with aregion (61) which is substantially free of fastening elements to providea finger lift region (62). In the FIG. 11 embodiment, the two opposingclosure system tab elements (63) and (64) cut from the closure systemweb are mirror images of each other; one providing the fastening tabportion and the attachment portion on one edge region of a disposableabsorbent garment; and the opposing tab element providing an opposingfastening tab portion and an attachment portion on the opposite edge ofthe disposable absorbent article. With this embodiment, there are twoseparate and distinct attachment portions (65) and (66) and no bridgingportion or band connecting the two terminal end portions or fasteningtab portions.

FIG. 12 illustrates how the FIG. 11 closure system tab elements (63) and(64) would be placed on the continuous web (41) forming a portion of thedisposable absorbent article providing two separate attachment portions(65) and (66) and two fastening tab portions.

Although the first fastening regions depicted in the above illustratedembodiments are provided by a mechanical fastening element, particularlya hook mechanical fastening material (4), attached to the backing (2) bya provided pressure sensitive adhesive layer (9), the first fasteningregion can be provided by other attachment materials or in other ways.Specifically, the first fastening region can be any suitable attachmentmaterial including hook or loop mechanical fastening materials orregions, pressure sensitive adhesive regions or patches, cohesiveadhesive regions or patches, and the like. Also other mechanicalfastening type materials are possible, such as snap fasteners, providedthat a suitable mating engagement surface is provided on the attachmentportion on the opposite face of the closure system web. Further thefirst fastening region can be provided as a separate element attached tothe backing (2) first face as shown in the drawings or can be integrallyformed with the backing (2), for example, the backing could be anextruded film material with molded hook fastening elements provided onlyat the terminal end portions thereof Alternatively, the first fasteningregion can be provided on a separate backing (6) which is attached tobacking (2) by suitable methods, such as hot melt or pressure sensitiveadhesives(as shown), heat or sonic welding, or other conventional means.

Where the first fastening region is provided by a pressure sensitiveadhesive it is not necessary that the surface to which the firstfastening region attaches be a surface provided by the second fasteningregion. For example, the closure system tab elements could be attachedto an inside surface of a continuous backsheet web such that the firstfastening region would attach to the backsheet web, or further web on abacksheet web, with the second fastening region of the closure systemtab element reinforcing the backsheet web at a location where the firstfastening region would attach to form a suitable tape fastening region.In this embodiment, the backing second face could be provided with asuitable pressure sensitive adhesive for attaching to the face of the,e.g., inside backsheet web. Alternatively, the backing second face couldbe attached to the backsheet web or a further web by other attachmentmethods as previously discussed.

The backing (2) for the closure system web (1) can be any suitable webproduct or laminate including film materials, foam products, fabrics,such as woven or non-woven webs, or multi-layer structures comprisingany or all of the above-mentioned materials and the like, whichmulti-layer structuring can be either continuous or intermittent acrossthe length and/or width of the backing (2). The backing (2 or 82) couldbe an elastic material with specific elastic region, such as (81)depicted in FIG. 13. This elastic region (81) can be provided byspecifically elasticating a region of the backing (2 or 82). In FIG. 13,the elastic backing (82) is formed as described in U.S. Pat. No.5,505,852 which discloses a coextruded inelastic multilayer film havingelastic (86) and inelastic layers (85 and 87) which multilayer film canbe selectively stretch activated to create an elastic, e.g., byselectively stretching in region (81) in the manner disclosed in U.S.Pat. No. 5,505,852. However, alternatively, the entire backing (2 or 82)can be made elastic such as by providing an elastomeric film or anelastomeric woven or non-woven material, or laminates thereof, as thebacking (2 or 82). In FIG. 13, the hook fastening material (4) isattached to an inelastic portion of the backing (82) by an adhesivelayer (89) which could be provided or coated on the hook material (4) oron the backing (82).

An alternative method of providing a zone of elasticity (81) on a filmbacking is shown in FIG. 15. In FIG. 15, the film backing is formed byselective side by side elastic and inelastic regions, for example, byside by side coextrusion of elastic and inelastic materials as disclosedin Japanese Appln. No. 8-187113. Alternatively, a side-by-side elasticand inelastic region could be provided by included elastic regionswithin an inelastic matrix as disclosed in U.S. Pat. No. 5,429,856.

An elastic backing material (12 or 82) can also be selectively bonded orlaminated to an inelastic film or other web material in an unextendedstate followed by selective stretching of the composite to provideelasticity as disclosed in U.S. Pat. Nos. 5,167,897; 5,156,793;5,143,679; or 5,527,304, or PCT WO 96/1048 (stretching is facilitated byselectively slitting the inelastic layer) or an elastic material can beapplied to a separate backing layer (e.g., a non-woven web) in astretched state either by intermittent or continuous attachment so as toallow the elastic material to recover resulting in the laminate backingmaterial of the laminate backing so formed gather or buckle betweenattachment points forming an elastic composite in that region.Separately applied elastic material can also be applied to either thefirst or the second face of another continuous backing material whichcan also be elastic or inelastic, which other continuous backing couldbe stretched, unstretched or gathered, or corrugated when attached tothe elastic material.

The loop materials (8) or (88) can be any conventional woven ornon-woven loop material which is suitably attached to the backing (2) or(82) as would be known in the art.

FIG. 14 shows an alternative embodiment of the invention where a loopfabric is selectively provided to be engagable with a hook material inregion (83) and generally less engagable with the hook material inregion (84). Loop fabric is applied to a film backing (82). This can beaccomplished by taking a relatively low loft non-woven type fabric andcausing it to selectively gather or corrugate in region (81) and besubstantially flat in region (84) which region (84) can further beconsolidated as required. This can be accomplished by using the methoddepicted in FIG. 3 by selectively providing corrugations or undulationsin the web (3) only in the region or the second portion forming theattachment portion on the second face of the closure system web.Suitable non-woven materials for forming the loop material aredisclosed, for example, in U.S. Pat. Nos. 5,256,231; 5,614,281;5,032,122; 5,470,417; 5,326,612, and WO 96/04812, WO 95/33390.

FIG. 15 shows an alternative embodiment where a backing (107) isside-by-side coextruded to have inelastic regions (104 and 106) oneither side of an elastic region (105). Further, an inelastic region(106) are formed integral hook elements. An inextensible web (103) isattached to first face of the backing and in at least elastic region(81) is corrugated by the method shown in FIG. 3 or otherwise compressedin its width dimension as is shown in the art. On the second face of thebacking is provided a loop material (108) which is shown as corrugatedby the method shown in FIG. 3 across its full width allowing the elasticregion (8) to elongate and provide a substantially loop attachmentportion.

The invention further provides a method of forming a closure system fora disposable absorbent article comprising the steps of, providing atleast one continuous or substantially continuous web capable of forminga portion of a disposable absorbent article. This web has at least afirst width dimension defining two side edges and an indefinite lengthdimension. A closure system web is also provided comprising at least onebacking having a first face and a second face. The closure system webhas a second width dimension greater than the first width dimension andan indefinite length. The first face of the closure system web isprovided with at least one first fastening region at at least oneterminal end portion of the closure system web. At least one secondfastening region is provided on the second face of the closure systemweb in at least the second portion adjacent the terminal end portionprovided with the first fastening region. Closure system tab elementsare cut from the closure system web which tab elements have a definitelength dimension. The closure system tab elements have at least onefastening tab portion, comprising the at least one first fasteningregion on the terminal end portion, and an attachment portion comprisingthe second portion having the second fastening region.

The closure system tab elements are then attached to the at least onecontinuous or substantially continuous web at regular spaced intervalsin the indefinite length dimension in a continuous manner forming asecond continuous web. The second continuous web is then cut alongtransverse cut lines in the indefinite length dimension. The cut linesare such that they bisect the closure system tab elements along the tabelement definite length dimension, so that the fastening tab portion ison a first side of the cut line and the attachment portion is on asecond opposing side of the cut line. This provides fastening tabportions on a first end of one absorbent article and an attachmentportion on a second end of an adjacent absorbent article. Preferably thetransverse cut line also forms the discrete absorbent article.

We claim:
 1. A method of forming a closure system for a disposableabsorbent article comprising the steps of:providing at least onecontinuous or substantially continuous web, the web capable of forming aportion of a disposable absorbent article, the web having a first widthdimension defining two side edges and an indefinite length dimension,providing a closure system web comprising at least one backing having afirst face and a second face, a second width dimension and an indefinitelength, the first face being provided with at least one first fasteningregion at at least one terminal end portion of the closure system web,at least one second fastening region being provided on the second faceof the closure system web in a second portion of the closure system webadjacent the terminal end portion provided with the first fasteningregion, cutting closure system tab elements having a definite lengthdimension from the closure system web, the closure system tab elementshaving at least one fastening tab portion, comprising the at least onefirst fastening region on the terminal end portion, and an attachmentportion comprising the second portion having the second fasteningregion, wherein the first fastening tab portion is offset from theattachment portion in the length direction of the closure system web;continuously attaching the closure system tab elements to the at leastone continuous or substantially continuous web at a location having thefirst width dimension at regular spaced intervals in the indefinitelength dimension of the at least one continuous or substantiallycontinuous web, cutting the at least one continuous web along cut lines,which cut lines are transverse to the indefinite length dimension to,wherein the transverse cut lines are such that each bisects the closuresystem tab element along its definite length such that the at least onefastening tab portion is on a first side of a transverse cut line andthe offset attachment portion is on a second opposing side of thetransverse cut line so as to provide a fastening tab portion on thefirst end of one absorbent article and an attachment portion on a secondend of an adjacent absorbent article.
 2. The method of claim 1 furthercomprising joining the at least one continuous or substantiallycontinuous web to further elements to form a continuous absorbentarticle web and wherein the transverse cut line forms discrete absorbentarticles and the at least one first fastening tab portion attached tothe absorbent article has a first end extending outwardly beyond theside edges of the absorbent article and a second end attached to theabsorbent article, at least the first end having said first fasteningregion.
 3. The method of claim 2 wherein there are two terminal endportions of the closure system web provided with a first fasteningregion which are connected by a portion of the closure system web secondportion on the first side of the transverse cut line.
 4. The method ofclaim 3 wherein the second portion on the first side of the transversecut line has an average length less than average length of the secondportion on the second side of the cut line.
 5. The method of claim 4wherein the average width of the second portion on the first side of thetraverse cut line is greater than the average width of the secondportion on the second side of the transverse cut line.
 6. The method ofclaim 4 wherein the average length of the second portion on the firstside of the transverse cut line is less than 50 percent of the averagelength of the second portion on the second side of the transverse cutline.
 7. The method of claim 6 wherein the two terminal end portions areonly on the first side of the transverse cut line.
 8. The method ofclaim 2 wherein the closure system web second portion on the first sideof the transverse cut line is a negative inverted mirror image of thesecond portion on the second side of the transverse cut line for aclosure system tab element such that the two second portions if combinedwould form a rectangular second portion.
 9. The method of claim 2wherein the first fastening region comprises a pressure sensitiveadhesive patch.
 10. The method of claim 9 wherein the first fasteningregion pressure sensitive adhesive patch is provided on the at least onebacking.
 11. The method of claim 10 wherein the first fastening regionpressure sensitive adhesive patch is provided on a tape backing firstface with the second face attached to the at least one backing.
 12. Themethod of claim 1 wherein the first fastening region comprises amechanical fastening patch and the attachment portion comprises a matingmechanical fastening patch.
 13. The method of claim 12 wherein themechanical fastening patch comprises a hook mechanical fastening patchand the mating mechanical fastening patch comprises a loop mechanicalfastening patch.
 14. The method of claim 13 wherein the hook mechanicalfastener patch comprises a backing having hook mechanical fasteningelements projecting from a first face and a second face attached to theclosure system web at least one backing.
 15. The method of claim 13wherein the loop mechanical fastening patch comprises the closure systemweb at least one backing.
 16. The method of claim 13 wherein the loopmechanical fastening patch is a loop fabric attached to the closuresystem web at least one backing.
 17. The method of claim 1 wherein thefirst face of the at least one backing is provided with a pressuresensitive adhesive for attachment of the closure system tab elements tothe at least one continuous web of the disposable absorbent article. 18.The method of claim 1 wherein the closure system tab elements are cut ina general u-shape.
 19. The method of claim 1 wherein at least theterminal end portions are provided with elastic regions.
 20. The methodof claim 19 wherein the elastic regions are adjacent the first fasteningregion.
 21. The method of claim 20 wherein the elastic region is on thefirst end of the terminal end portion adjacent the side edge andoutboard of the absorbent article.
 22. The method of claim 20 whereinthe elastic region is provided by laminating an elastic sheet to theclosure system web at least one backing.
 23. The method of claim 2wherein the first fastening region is a hook mechanical fastener on thefirst end of the fastening tab portion with the second end of thefastening tab portion on the first face having a mating loop materialfor temporary attachment of the hook mechanical fastener prior to use.24. The method of claim 1 wherein the second portion is between twoterminal end portions and the tab element forms at least two fasteningtab portions and an intermediate attachment portion.
 25. The method ofclaim 1 wherein the terminal end portions are between two secondportions on the closure system web such that two closure system tabelements are cut from left and right edges of the closure system web,one closure system tab element from each edge of the closure system webare placed along each edge of the continuous web forming the disposableabsorbent article such that each transverse cut line forms two fasteningtab portions and two attachment portions on adjacent absorbent articles.26. The method of claim 1 wherein the closure system web at least onebacking is at least in part elastic.
 27. The method of claim 1 whereinthe closure system web at least one backing is at least in partinelastic.
 28. The method of claim 27 wherein the closure system web atleast one backing is at least in part inextensible.
 29. The method ofclaim 26 wherein the closure system web at least one backing is anelastic film.
 30. The method of claim 27 wherein the closure system webat least one backing is an inelastic film.
 31. The method of claim 1wherein the closure system web at least one backing is a laminate of afilm layer and a non-woven material.
 32. The method of claim 1 whereinthe second width dimension is greater than the first width dimensionsuch that the first fastening region extends out beyond the side edgesof the disposable absorbent article.
 33. The method of claim 1 whereinthe maximum length of the fastening tab portion is from 2 to 10 cm. 34.The method of claim 1 wherein the fastening tab portion maximum lengthis from 2 to 6 cm.
 35. The method of claim 1 wherein the fastening tabportion first fastening region is on average from 0.5 to 5 cm long. 36.The method of claim 1 wherein the fastening tab portion first fasteningregion has a cross sectional area of from 1 to 10 cm².
 37. The method ofclaim 2 wherein the fastening tab portion second end has a minimum widthof from 1 to 5 cm.
 38. The method of claim 1 wherein the attachmentportion average length is from 40 to 95 percent of the average length ofthe first fastening region.
 39. The method of claim 2 wherein theattachment portion average length is from 60 to 90 percent of theaverage length of the first fastening region.
 40. The method of claim 1wherein the maximum length of the closure system tab element is from 10to 100 cm.